Custom Full-Size Door

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Project by Shawn Herrington posted 09-20-2014 05:10 AM 1389 views 1 time favorited 4 comments Add to Favorites Watch

I failed to take a picture of the abomination that previously occupied this door jamb. Suffice it to say, the lowest rail of the door looked like it had been eaten by a badger. Someone named “knuckle head” (names have been changed to protect the identity of the guilty) attempted to fix the big badger holes with a ludicrous amount of wood filler which simply made the door uglier.

This door was made to imitate the doors of the cabinets (most visible in the last two pictures) as well as to mirror the gray bead-board and white border on the wall (visible in the second picture). I built the door slightly over-sized based on the dimensions of the existing door jamb then planed it for an even reveal after fitting the hinges. Once installed, I fitted the latch to engage with the existing mortise and strike plate.

The rails and stiles are dadoed to accept the bead-board panel as well as the stub tenons on the rails. There is a bevel reveal surrounding the bead-board panels. Initially, I planned to cut the bevel with a table saw but instead elected to cut it by the old fashioned way with hand planes to remove most of the material, and chisels to clean up the mitered corners.

The door was primed then painted to match the wall it was built to mimic.

-- -Shawn

4 comments so far

View wseand's profile


2796 posts in 4285 days

#1 posted 09-22-2014 03:43 AM

Very nice door. Sometimes better to replace then to try to fix the POS.


View BinghamtonEd's profile


2298 posts in 3613 days

#2 posted 09-23-2014 02:52 PM

Nice work. What did you use for the rails/stiles, I assume some straight-grained hardwood?

-- - The mightiest oak in the forest is just a little nut that held its ground.

View dbray45's profile


3414 posts in 4020 days

#3 posted 09-23-2014 02:58 PM

Good Job, well executed.

-- David in Palm Bay, FL

View Shawn Herrington's profile

Shawn Herrington

28 posts in 2605 days

#4 posted 09-25-2014 03:13 AM

Nice work. What did you use for the rails/stiles, I assume some straight-grained hardwood?

- BinghamtonEd

It is actually straight grained pine because it was easy to get and cheap. It was tough to get the door assembled and installed without denting the material since it is so soft but now that it is installed and painted I think it will hold up just fine. The old door was pine as well; of course it was from an old tree with very tight grain.

-- -Shawn

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